Pile extruder

ABSTRACT

A STAPLING ATTACHMENT IS SECURED UPON EACH SIDE OF A PILE EXTRUDING MACHINE SO THAT U-SHAPED REINFORCING STAPLES CAN BE INSERTED UPON EACH SIDE OF THE PILE AT SPACED INTERVALS THEREALONG, AS THE PILE IS BEING EXTRUDED. ALSO THE EXTRUDING MACHINE IS IN TWO PORTIONS, A POWER UNIT AND AN AGER UNIT THUS ENABLING THE RELATIVELY EXPENSIVE POWER UNIT TO BE USED ON DIFFERENT BEDS OR PALLETS.

Sept. 20, 1971 E, MARTENS EI'AL PILE EXTRUDER 3 Sheets-Sheet 2 Filed Oct. 21. 1968 Sept- 20 1971 E. MARTENS EVAL PILE EXTRUDER Filed Oct. 21, 1968 3 Sheets-Sheet 3 UnitedV States Patent @ce 3,605,217 PILE EXTRUDER Ernest Martens, 75 Noble Ave.; Adalbert Groll, 346 Edward Ave.; and Frederick Maxwell Hewitt, 349 Kingston Crescent, all of Winnipeg, Manitoba, Canada; and Ambros Leitbner, Manitoba, Canada Filed Oct. 21, 1968, Ser. No. 801,214 (Filed under Rule 47(a) and 35 U.S.C. 116) Int. Cl. B28b 3/22 U.S. Cl. 25-14 18 Claims ABSTRACT OF THE DISCLOSURE A stapling attachment is secured `upon each side of a pile ex'truding machine so that U-shaped reinforcing staples can be inserted upon each side of the pile at spaced intervals therealong, as the pile is being extruded. Also the extruding machine is in two portions, a power unit and an auger unit thus enabling the relatively expensive power unit to be used on different beds or pallets.

This device relates Ito new and useful improvements in pile extruders, particularly machines for extruding prestressed concrete hollow-core piles and other sections.

The basic principles of extrusion which are embodied in this device are already shown in various Canadian, U.S. and British patents, such as Canadian Pat. Nos. 623,476 and 720,048, U.S. Pat. Nos. 3,159,897 and 3,284,867, and British Pat. No. 994,578.

Also of interest is U.S. Palt. No. 3,529,330 dated Sept. 22, 1970, entitled Device for Inserting Transverse Reinforcing Members in Slabs Formed by Concrete Slab Extruding Machines.

Extruding devices as described above are capable of making hollow-core concrete slabs and normally there is no necessity for reinforcing steel ties or stirrups. However, in certain circumstances, transverse steel bars are used in the upper surface of these llat slabs and the above mentioned patent shows a method of inserting these transverse bars in the flat slabs.

This method, described in the patent places these bars by means of an hydraulically operated carriage which carries the bars into the extruded slab in the direction of extrusion, that is, opposite to the motion of the extruder. While this system may be satisfactory for flat slabs, it is not suitable for other sections, particularly sections used for piles and the like.

For sections such as used for piles, stirrups or ties are required to enclose the prestressing strands around which the section is extruded.

Normally piles and similar sections are formed by the wet pour method in moulds having base plates and side plates. Under these circumstances spiral ties are utilized because they are easily positioned and fixed in place, Whereas placing single ties under these circumstances would involve considerable time and labour.

When making piles and similar sections by the extru sion method, the insertion of spiral reinforcement is very cumbersome and uneconomical and therefore it has been decided that separate individual split ties would be used.

In conjunction with the extruding machine described in the above mentioned patents, wel have provided apparatus for inserting split ties utilizing a hydraulic stapler.

One problem which has to be overcome with the machine used for the extrusion of piles and similar sections, Which does not occur with slab extrusion, is the inability to remove the auger assembly and bearing housing from the casting bed after a pile has been extruded. This is because the prestressed cables surrounding the auger are guided in apertures through the bearing housing.

3,605,217 Patented Sept. 20, 1971 We have overcome this disadvantage as will hereinafter be described by forming the extruder into two units, the major and relatively expensive portion being readily removable and usable on other beds.

yWith the foregoing in view, and such other of further purposes, advantages or novel features as may become apparent from consideration of this disclosure and specification, the present invention consists of the inventive concept which is comprised, embodied, embraced or included in the method, process, construction, composition, arrangement of parts, or new use of any of the foregoing, herein exemplified in one or more specific embodiments of such concept, reference being had to the accompanying figures in which:

FIG. 1 is a schematic plan view of the pile extruder with the upper plate removed for clarity.

FIG. 2 is a longitudinal elevation along the line 2-2 of FIG. 1.

FIG. 3 is a section along the line 3 3 of FIG. 1.

FIG. 4 is a section along the line 4 4 of FIG. 3.

FIG. 5 is an isometric exploded view showing the stapler portion of the device.

FIG. 6 is a cross sectional View of a 14 square pile with the staples inserted.

FIGS. 7 and 8 are isometric views of other sections showing alternative methods of placing the reinforcing cross ties.

FIG. 9 is a cross sectional view showing a pile extruded onto a conventional bed plate or pallet.

In the drawings like characters of reference indicate corresponding parts in the different figures.

Proceeding therefore to describe lthe invention in detail, reference character 1 illustrates a bearing housing or plate which carries the bearings for auger drive shaft 2 and the auger 3.

A high speed motor 4 is mounted rearwardly of the bearing plate 1 and is connected to the drive shaft 2 for driving a vibrator (not illustrated) inside the auger.

The bearing plate 1 together with the auger drive shaft and motor are secured to the underside of a platform or plate 5 together with sprocket 6 secured to drive shaft 2.

A smaller sprocket 7 engages sprocket 6 but forms part of a separate assembly detachably securable to plate 5 and being positioned by locating pins 8.

A motor 9 supplies the power to drive the auger 3 and this drive is imparted by means of gear box 10, chain drive 11 and intermediate shaft 12 which carries the aforementioned sprocket 7 engageable with the Ysprocket 6.

The assembly containing motor 9, gearbox 10, chain drive 11 and the intermedi-ate shaft 12 with sprocket 7 is mounted upon plate 13 which carries the aforementioned guide pins 8 engageable within plate 5, it being understood that conventional bolt means (not illustrated) are provided to bolt the assemblies together.

The assembly mounted on plate 13 is identified as the power unit whereas the assembly permanently fixed to plate 5 is referred to as the auger unit.

In order to feed concrete mix to the auger flight 3 we provide a hopper 14 which in turn feeds the concrete mix to three screw conveyors 15 which discharge the mix to the flights of the auger. It has been found desirable to provide the three screw conveyors in order to ensure rapid distribution of the concrete mix around the reinforcing wires prior to the augering action compacting same.

Each of the screw conveyors is driven by a motor 16 through a chain drive 17. The hopper 14 and the conveyor assemblies 15, 16 and 17 form part of the power unit and are permanently mounted to plate 13. The power unit is mounted upon the frame 18 which supports the 3 complete power unit and runs on four wheels 22 which in turn run on a pair of parallel rails 22A bounding the sides of bed plate or pallet 22B (see FIG. 9).

The pile itself is formed in a moulding chamber 3A through which the auger 3 forces the concrete mix. The auger itself forms the inside circular core of the pile and the bottom face of the pile is formed by the stationary pallet 22B over which the extruder moves. Each of the side faces is formed by a side plate 19 and the top face is formed by a trowelling unit 21. The side plates 19 and the trowelling unit 21 are also permanently fixed to the power unit for the purposes of extrusion. This moulding chamber assembly is similar in construction to the moulding chamber described in the above mentioned patents.

To facilitate compaction of the concrete mix while being angered, there is a vibrator inside the auger 3 driven by motor 4 and a further vibrator unit 20 mounted adjacent the trowelling unit and this vibrator unit 20 is resiliently or elastically connected to the frame 18 to impart the necessary vibration.

A stapler assembly generally referred to as 19A is situated on either side of the auger 3 externally of the side plates 19.

This stapler 19A is for inserting staples 23 through a slot 24 (see FIGS. 1 and 2), formed in each of the side plates 19. Fingers 25 are formed on the end of slide plate 26 and these ngers force the staples through the slots 24 and into the concrete mix so that they take up the po sition shown in FIG. 6. The plate 26 is then withdrawn ready for the next staple. An hydraulic motor 27 provides driving force for plate 26, motoi. 27 having sprocket 28 secured thereto, said sprocket engaging with ratchet or rack 29 which in turn is fixed to plate 26. We have found that the insertion of the staples is facilitated if a vibrator 30 is used, said vibrator being mounted on plate 26 and moving therewith.

The plates 26 are mounted for endwise sliding motion in upper and lower guides 26A, held by straps 26B, one of rwhich mounts the hydraulic motor 27. These guides and straps are secured to the frame 26C of the assembly adjacent the side plates 19 and extend outwardly therefrom, one upon each side of the assembly, as clearly shown in FIG. l.

The staples 23 which are U-shaped, are mounted on a guide 31 along which they are fed to the stapler. The staples are forced towards the stapler by pressure plate 32 which in turn is driven by the piston of hydraulic cylinder 33.

The guide 31 is formed from a pair of channel members 31A spaced apart as shown in FIG. 5 so that the pressure plate 32 passes therebetween and engages the staples by the legs 23'.

The channel members are secured to the frame 26C and run parallel thereto. The inner ends 31B are spanned by braces 31C to maintain the channels in the said spaced apart relationship and these inner ends terminate adjacent the slots 24 leaving a space suicient to permit entry f the stapler plate 26 and ngers 25 together with the end staple 23 picked up and carried by the lingers. A base plate 31B under this gap supports the staple as it leaves the end of the guide 31 prior to the entry of this staple into the slot 24.

FIIG. 6 shows the cross sectional view of a square cross section pile 34 having longitudinally extending prestressed strands or wires 35. Staples 23 have been inserted upon either side and take up the position shown in FIG. 6 With the ends of the staples having a considerable overlap as indicated at 36, thus giving the desired strengthening effect to the formed pile.

It will of course be understood that these staples are inserted in pairs one upon each side and that the spacing between pairs of staples can be varied as desired. Either manual or automatic control can be used to set the spaces.

FIGS. 7 and 8 show alternative forms of the invention FIG. 7 having an octagonal cross section and FIG. 8 having a rectangular cross section.

In both cases it will be noted that a split stirrup or tie has been utilized, reference character 37 indicating the major portion thereof which, of course, can be engaged around the longitudinally extending reinforcing wires prior to the pile being extruded.

As the pile is extruded, a single staple 23 may be engaged or inserted in order to close the stirrup or tie.

In summary, the following improvements are applied to the extruded sections and to the pile extruder as follows:

(l) Split ties or staples are used instead of helical windings.

(2) One or both sections of each tie or staple is automatically inserted into the section during the extrusion process.

(3 )Split stirrups are used instead of continuous stirrups.

(4) One or both sections of the split stirrups is inserted automatically during extrusion.

`(5) The extruding machine can be split into two units; namely the auger unit and the power unit. Therefore only one power unit need be used to operate several auger units as an auger unit per casting bed can then be used without the necessity of having a power unit for each bed.

(6) Because of the locations of the prestressing strands, it is necessary to feed the mix to the auger by means of screw conveyors. These are used to distribute the mix evenly across the section of the pile and before compaction commences.

(7) In order to correctly locate the prestressing strands and to prevent them from being moved by the movement of the concrete mix and the movement of the machine, they are fed through the machine in steel tubes 34A which are secured to the bearing plate or housing 1 and are shown in FIG. 4.

(8) Staples are automatically inserted in the pile during extrusion by stapler assemblies or components s1tuated upon each side thereof.

Various modifications can be made within the scopeof the inventive concept disclosed. Accordingly, it is intended that what is described herein should be regarded as illustrative of such concept and not for the purpose of limiting protection to any particular embodiment thereof, but that only such limitations should be placed upon the scope of protection to which the inventor hereof is entitled, as justice dictates.

What is claimed to `be the present invention is:

1. A pile extruder comprising in combination a power u nit and an auger unit detachably secured to the underside of said power unit, said power unit including a base plate, a hopper supported by said base plate, a source of power on said base plate, a moulding chamber on the rear end of said base plate, and distribution augers extending from said hopper to said auger unit, said auger unit `being detachably secured to the underside of said base plate and being operatively connected to said source of power.

2. The extruder according to claim 1 in which said auger unit includes a mounting plate detachably securable to said base plate, a vertically situated bearing plate supported by said mounting plate, an auger supported for rotation by one end thereof in said bearing plate, and drive means extending from said one end of said auger to said source of power.

3. The pile extruder according to claim 1 which includes a stapler assembly adjacent said moulding chamber, staples at spaced intervals into the pile being extruded stapler assembly including means to inject reinforcing through said moulding chamber, and slot means on one said stapler assembly including means to inject reinforcing staples at spaced intervals into the pile being extruded side of said moulding chamber through which said staples are injected.

4. The pile extruder according to claim 2 which includes a stapler assembly adjacent said moulding chamber, said through said moulding chamber, and slot means on one side of said moulding chamber through which said staples are injected.

5. The pile extruder according to claim 3 in which said stapler assembly includes an endwise movable slide plate and a guide, said guide supporting said staples prior to said injection thereof, said guide terminating in spaced relationship from said slide plate and on one side of slot means.

6. The pile extruder according to claim 3 in which said means for injecting said staples includes a slide plate, guide members in which said slide plate reciprocates, staple engaging lingers on one end of said slide plate, a source of power on said stapler, and means operatively connecting said slide plate with said source of power.

7. The pile extruder according to claim 4 in which said means for injecting said staples includes a slide plate, guide members in which said slide plate reciprocates, staple engaging fingers on one end of said slide plate, a source of power on said stapler, and means operatively connecting said slide plate with said source of power.

8. The pile extruder according to claim 6 in which said last mentioned means includes a rack bar on said slide plate and a gear rotated by said source of power engageable with said rack bar.

9. The pile extruder according to claim 7 in which said last mentioned means includes a rack bar on said slide plate and a gear rotated by said source of power engageable with said rack bar.

10. The pile extruder according to claim 5 in which said guide includes a pair of spaced and parallel members, means associated with said guide supporting said staples, to urge said staples towards said side plate, said last mentioned means including a pressure plate engageable between said spaced and parallel members, and a source of power for said pressure plate, said pressure plate engaging the legs of said staples supported on said members.

11. The pile extruder according to claim 6 in which said guide includes a pair of spaced and parallel members, means associated with said guide supporting said staples, to urge said staples towards said side plate, said last mentioned means including a pressure plate engageable between said spaced and parallel members, and a source of power for said pressure plate, said pressure plate engaging the legs of said staples supported on said members.

12. The pile extruder according to claim 7 in which said guide includes a pair of spaced and parallel members, means associated with said guide supporting said staples, to urge said staples towards said side plate, said last mentioned means including a pressure plate engageable between said spaced and parallel members, and a source of power for said pressure plate, said pressure plate engaging the legs of said staples supported on said members.

13. The pile extruder according to claim 8 in which said guide includes a pair of spaced and parallel members,

CII

means associated with said guide supporting said staples, to urge said staples towards said side plate, said last mentioned means including a pressure plate engageable between said spaced and parallel members, and a source of power for said pressure plate, said pressure plate engaging the legs of said staples supported on said members.

14. The pile extruder according to claim 9 in which said guide includes a pair of spaced and parallel members, means associated with said guide supporting said staples, to urge said staples towards said side plate, said last mentioned means including a pressure plate engageable between said spaced and parallel members, and a source of power for said pressure plate, said pressure plate engaging the legs of said staples supported on said members.

15. A stapler assembly for pile extruders which include a moulding chamber having spaced and parallel vertically situated side walls, and slot means within said side walls adjacent said stapler assembly through which the staples may be injected into the pile being extruded by the pile extruder; said stapler assembly comprising in combination means to inject reinforcing staples at spaced intervals into the pile being extruded through said moulding chamber, said last mentioned means including a slide plate mounted for endwise movement, and a guide for supporting said staples prior to said injection thereof, said guide terminating in spaced relationship from said slide plate and on one side of said slot means.

16. The stapler assembly according to claim 15 which includes upper and lower guide members for said slide plate, said slide plate reciprocating in said guide members, staple engaging fingers, on one end of said slide plate, a source of power on said stapler, and means operatively connecting said slide plate with said source of power.

17. The stapler assembly according to claim 16 in which said last mentioned means includes a rack bar on said slide plate and a gear rotated by said source of power engageable with said rack bar.

18. The stapler assembly according to claim 17 which includes means associated with said guide supporting said staples, to urge said staples towards said side plate, said guide including a pair of spaced and parallel members, said last mentioned means including a pressure plate engaging between said spaced and parallel members and a source of power for said pressure plate, said pressure plate engaging the legs of said staples supported on said spaced and parallel members.

References Cited UNITED STATES PATENTS 3,060,540 10/1962 Lapidus 25-41(.5A) 3,159,897 12/1964 Ellis et al. 25-4l(.5A) 3,284,867 11/1966 Booth 25--32 J. SPENCER OVERHOLSER, Primary Examiner L. R. FRYE, Assistant Examiner U.S. Cl. X.R. 25-1 

